Through-air apparatus with adjustable deckle

Abstract

A through-air apparatus for drying or bonding paper or non-woven products is provided. The apparatus includes a through air roll configured to rotate about a first axis, where the roll has a cylindrical surface having a plurality of openings configured for the flow of air there through. The apparatus also includes an air distribution tube positioned within the through air roll. The air distribution tube has a cylindrical surface, a first end, and a second end, and the cylindrical surface of the air distribution tube has a plurality of openings configured for the flow of air there through. The apparatus further includes a first adjustable deckle associated with the air distribution tube configured to alter the flow of air through the air distribution tube. The first adjustable deckle includes a first floating plate configured to selectively cover a first portion of the plurality of openings in the air distribution tube, and a first deckle wall, wherein the first deckle wall is movable independent of the first floating plate. A method of assembling a through-air apparatus for drying or bonding paper or non-woven products is also provided.

What is claimed is: 
     
       1. A through-air apparatus for drying or bonding paper or non-woven products, the apparatus comprising:
 a through air roll configured to rotate about a first axis, wherein the roll has a cylindrical surface, the cylindrical surface having a plurality of openings configured for the flow of air there through; 
 an air distribution tube positioned within the through air roll, the air distribution tube having an outer surface, a first end, and a second end, the outer surface of the air distribution tube having a plurality of openings configured for the flow of air there through; 
 a first adjustable deckle associated with the air distribution tube, the adjustable deckle configured to alter the flow of air through the air distribution tube, the first adjustable deckle comprising:
 a first floating plate configured to selectively cover a first portion of the outer surface of the air distribution tube; and 
 a first deckle wall, wherein the first deckle wall is movable independent of the first floating plate, and wherein movement of the first floating plate is initiated by movement of the first deckle wall. 
 
 
     
     
       2. The through-air apparatus of  claim 1 , wherein the first floating plate is selectively movable with the first deckle wall. 
     
     
       3. The through-air apparatus of  claim 1 , wherein the first adjustable deckle is positioned at the first end of the air distribution tube. 
     
     
       4. The through-air apparatus of  claim 3 , further comprising:
 a second adjustable deckle associated with the air distribution tube, the adjustable deckle configured to alter the flow of air through the air distribution tube, the second adjustable deckle comprising:
 a second floating plate configured to selectively cover a second portion of the outer surface the air distribution tube; and 
 a second deckle wall, wherein the second deckle wall is movable independent of the second floating plate. 
 
 
     
     
       5. The through-air apparatus of  claim 4 , wherein the second floating plate is selectively movable with the second deckle wall. 
     
     
       6. The through-air apparatus of  claim 4 , wherein the second adjustable deckle is positioned at the second end of the air distribution tube. 
     
     
       7. The through-air apparatus of  claim 6 , wherein the first and second adjustable deckles are both moveable together between a minimum deckle position and a maximum deckle position so that a distance between the first deckle wall and the second deckle wall can be determined based upon the width of a product to be positioned on the apparatus. 
     
     
       8. The through-air apparatus of  claim 4 , wherein the first floating plate and the second floating plate each further comprises a catch positioned at each end of the floating plates, wherein each catch on the first floating plate is configured to limit movement of the first deckle wall, and each catch on the second floating plate is configured to limit movement of the second deckle wall. 
     
     
       9. The through-air apparatus of  claim 1 , wherein the air distribution tube is concentric with the through air roll. 
     
     
       10. The through-air apparatus of  claim 1 , further comprising:
 a pipe positioned along the first axis, and wherein the air distribution tube is supported radially by the pipe. 
 
     
     
       11. The through-air apparatus of  claim 1 , wherein the first floating plate has a cylindrical surface with a plurality of openings there through, and wherein the first floating plate is configured to alter the flow of air through the air distribution tube. 
     
     
       12. The through-air apparatus of  claim 1 , wherein the first floating plate has a cylindrical solid surface, and wherein the first floating plate is configured to reduce the flow of air through a first portion of the air distribution tube. 
     
     
       13. The through-air apparatus of  claim 4 , wherein the first floating plate and the second floating plate each have a cylindrical surface with a plurality of openings therethrough, and wherein the first floating plate and the second floating plate are configured to alter the flow of air through the air distribution tube. 
     
     
       14. The through-air apparatus of  claim 4 , wherein the first floating plate and the second floating plate each have a cylindrical solid surface, and wherein the first floating plate and the second floating plate are configured to reduce the flow of air through a first portion and a second portion of the air distribution tube. 
     
     
       15. A through-air apparatus for drying or bonding paper or non-woven products, the apparatus comprising:
 a through air roll configured to rotate about a first axis, wherein the roll has a cylindrical surface, the cylindrical surface having a plurality of openings configured for the flow of air there through; 
 an air distribution tube positioned within the through air roll, the air distribution tube having an outer surface, a first end, and a second end, the outer surface of the air distribution tube having a plurality of openings configured for the flow of air there through; 
 a first adjustable deckle associated with the air distribution tube, the adjustable deckle configured to alter the flow of air through the air distribution tube, the first adjustable deckle comprising:
 a first floating plate configured to selectively cover a first portion of the outer surface of the air distribution tube; and 
 a first deckle wall, wherein the first deckle wall is movable independent of the first floating plate; and 
 
 wherein the first adjustable deckle has a multi-plate configuration where the first floating plate includes a first floating plate portion and a second floating plate portion which are each movable and are configured to selectively cover a portion of the plurality of openings in the air distribution tube. 
 
     
     
       16. A through-air apparatus for drying or bonding paper or non-woven products, the apparatus comprising:
 a through air roll configured to rotate about a first axis, wherein the roll has a cylindrical surface, the cylindrical surface having a plurality of openings configured for the flow of air there through; 
 an air distribution tube positioned within the through air roll, the air distribution tube having an outer surface, a first end, and a second end, the outer surface of the air distribution tube having a plurality of openings configured for the flow of air there through; 
 a first adjustable deckle associated with the air distribution tube, the adjustable deckle configured to alter the flow of air through the air distribution tube, the first adjustable deckle comprising:
 a first floating plate configured to selectively cover a first portion of the outer surface the air distribution tube; and 
 a first deckle wall, wherein the first deckle wall is movable independent of the first floating plate; and 
 
 wherein the first floating plate of the first adjustable deckle further comprises a catch positioned at each end of the first floating plate, wherein each catch is configured to limit movement of the first deckle wall. 
 
     
     
       17. A method of using a through-air apparatus for drying or bonding paper or non-woven products, the method comprising:
 providing a through air roll configured to rotate about a first axis, wherein the roll has a cylindrical surface having a plurality of openings configured for the flow of air there through; 
 providing an air distribution tube positioned within the through air roll, the air distribution tube having a first end, and a second end, and an outer surface having a plurality of openings configured for the flow of air there through; and 
 moving a first floating plate of a first adjustable deckle relative to the air distribution tube to alter the flow of air through the air distribution tube, wherein the first floating plate is configured to selectively cover a first portion of the outer surface in the air distribution tube; and wherein movement of the first floating plate is initiated by movement of a first deckle wall of a first adjustable deckle, wherein the first deckle wall is movable independent of the first floating plate. 
 
     
     
       18. The method of  claim 17 , further comprising:
 moving a second floating plate of a second adjustable deckle relative to the air distribution tube to alter the flow of air through the air distribution tube, wherein the second floating plate is configured to selectively cover a second portion of the plurality of openings in outer surface in the air distribution tube; and wherein movement of the second floating plate is initiated by movement of a second deckle wall of a second adjustable deckle, wherein the second deckle wall is movable independent of the second floating plate. 
 
     
     
       19. The method of  claim 18 , wherein the first and second adjustable deckles are both moveable between a minimum deckle position and a maximum deckle position so that a distance between the first deckle wall and the second deckle wall can be positioned based upon the width of a product to be positioned on the apparatus. 
     
     
       20. The method of  claim 17 , wherein the first floating plate is selectively movable with the first deckle wall.